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Project
Shell Project No: HP-3000-QAT
Project Document Number: T- 4.250.931
2MH127
Tag/Item Number(s):
N/A
Unit(s):
ASU
PCWBS:
LINDE ENGINEERING
Page 2 of 19
5887
21.04.2008
BR
UA
ZG
RFC
10.12.2007
BR
AU/MC
ZG
ICC
26.11.2007
BR
AU/MC
ZG
IFR
20.11.2007
BR
AU/MC
ZG
IIR
Date
Description
GAMA
Rev.
No.
Project
Rev
No.
Status
Document Title:
LINDE ENGINEERING AG
Document No.
Contractor
LOC470
GAM
PRO
QAC
GTL
038
Org.
Code
Doc.
Type
Disc.
Code
Geogr.
Area
Seq.
No
Rev.
No
Vendor Code
Rev No: A
Q A T A R
Doc. Title
Doc. No:
GAM-PRO-QAC-GTL-038 Rev. D
Date
21.04.08
TABLE OF CONTENTS
1.
SCOPE ________________________________________________________________________5
2.
PURPOSE _____________________________________________________________________5
3.
HSSE _________________________________________________________________________5
4.
REFERENCES _________________________________________________________________5
5.
DEFINITIONS _________________________________________________________________6
6.
SAFETY _______________________________________________________________________6
7.
RESPONSIBILITIES ____________________________________________________________7
7.1.
7.2.
Welding Inspector__________________________________________________________________7
7.3.
7.4.
8.
EQUIPMENT___________________________________________________________________8
9.
PROCEDURE __________________________________________________________________8
9.1.
GENERAL _______________________________________________________________________8
10.
11.
12.
QUALITY ASSURANCE_______________________________________________________13
13.
ATTACHMENTS_____________________________________________________________14
T-4.250.931 REV-A
Page 4 of 19
Q A T A R
Doc. Title
Doc. No:
GAM-PRO-QAC-GTL-038 Rev. D
Date
21.04.08
1. SCOPE
The scope of this procedure is to present the controls adopted by GAMA-QATAR for
storage, handling, identification, conditioning and issue of welding consumables to be
applied in the C2 ASU PEARL GTL PROJECT.
2. PURPOSE
The purpose of this procedure is to define the requirements for consumable handling and
assign corresponding responsibilities.
3. HSSE
All works shall be in compliance with the State of Qatar laws and regulations, Ras Laffan
Industrial City and International standards, codes, LINDE ENGINEERING AG and QSGTL
and/or its PMC requirements and instructions.
In addition all employees and GAMA subcontractor employees on site will have through
LINDE ENGINEERING AG Site Safety Induction and GAMA Qatar Safety induction for site
safety, health, environmental and security prior to work activities. Other training courses will
be attended as required by LINDE ENGINEERING AG or QSGTL and/or its PMC as
required.
4. REFERENCES
ASME Section IX: Welding & Brazing Qualification
ASME Section II: Part C- Specification for Welding Rods, Electrodes
And Filler Metals
T-13.377.441: Quality control requirements for welding
T-13.377.438: Specification for Traceability, Alloy verification and material
substitution
T.4.096.687: Welding Consumable control
DEP 31.38.01.31 GEN: Shop and field fabrication of piping
DEP 30.10.60.18-Welding of metal (Amendments/supplements to API RP 582)
T-4.250.931 REV-A
Page 5 of 19
Q A T A R
Doc. Title
Doc. No:
GAM-PRO-QAC-GTL-038 Rev. D
Date
21.04.08
5. DEFINITIONS
Company
Contractor
: LINDE ENGINEERING AG
Sub Contractor
: GAMA QATAR
Contract
ITP
QCP
QCR
WPS
PQR
WPQT
NDT
WQT
SMAW
SAW
GTAW
GMAW
6. SAFETY
T-4.250.931 REV-A
Page 6 of 19
Q A T A R
Doc. Title
Doc. No:
GAM-PRO-QAC-GTL-038 Rev. D
Date
21.04.08
7. RESPONSIBILITIES
Responsibilities of project personnel relative to this procedure are described below:
7.1.
Prepares the welding procedures and requirements for consumables as per the approved
welding procedures.
Reviews purchase requisitions to ensure correct order specifications.
Reviews welding consumable batch certificates accordance with ISO10474 3.1B
specification.
Establishes re-order levels for welding consumables in line with project requirement.
Supervises Consumable Room personnel and operations.
Compiles Welding Consumables Identification Tables.
Compiles Welding Consumables Conditioning Instructions.
Has a responsibility for welding consumables control up the time of issue.
7.2.
WELDING FOREMAN
7.4.
WELDING INSPECTOR
Carries out Daily inspection/audit of the consumable room operations according to the
requirements of this procedure.
Monitors, oven, hoppers and portable quiver(s) temperature on site and check calibration
status is valid.
Monitors implementation of this procedure.
Carries out weekly documented surveillance of consumables usage on site (check list)
7.3.
WELDING ENGINEER
CONSUMABLE STORE-MAN
T-4.250.931 REV-A
Page 7 of 19
Q A T A R
Doc. Title
Doc. No:
GAM-PRO-QAC-GTL-038 Rev. D
Date
21.04.08
8. EQUIPMENT
Baking and holding ovens and portable heated quivers for use with SMAW consumables
will be designed for that purpose. All these items shall be checked and calibrated
periodically in accordance with T-4-250-915.
All calibration certificates shall be retained and filed for future reference and kept at the
QA/QC department.
9. PROCEDURE
9.1.
GENERAL
Purchase
Purchase orders shall be reviewed by the Welding Engineer to ensure correct and
adequate specification with respect to approved brand, and testing/certification
requirements. All certification shall be retained and filed for reference. All certification to
be submitted to Linde for approval before using.
T-4.250.931 REV-A
Page 8 of 19
Q A T A R
Doc. Title
Doc. No:
GAM-PRO-QAC-GTL-038 Rev. D
Date
21.04.08
Receipt
Incoming welding consumables shall be unloaded to an area segregated from other
certified stock. The Storekeeper shall receive deliveries of welding consumables
checking brand, AWS class, size, quantity and packing is as per the purchase order and
delivery document, and that certification is provided. Packaging shall be examined for
damage, which shall be reported to the Welding Engineer to determine the effect of
damage and advise disposition.
The consumable certification shall be reviewed by the Welding Engineer to determine
conformance with order specification and he shall endorse the certificate accordingly.
Return of the certificate to the Store man shall release the consumable for entry to stock
and transfer to bulk storage area in the warehouse.
Stacking of electrodes shall be carried out as per manufacture(s) recommendations.
Tagging of the electrodes is not required as electrodes are clearly marked by the
manufacturer(s) and they are separated in the consumable store based on their trade
name, AWS number and size.
T-4.250.931 REV-A
Page 9 of 19
Q A T A R
Doc. Title
Doc. No:
GAM-PRO-QAC-GTL-038 Rev. D
Date
21.04.08
< 60%
< 50%
< 40% Relative humidity
The QC Inspector on a daily basis, using a thermometer and hygrometer and reported
on the GAM-QCR-QAC-GTL-061, shall check consumable room atmospheric
conditions.
The consumables shall be segregated by AWS class (e.g. SMAW electrode, SAW flux,
SAW wire, GTAW wire etc.), brand, and size - batch and shall be maintained in original
packaging until split for conditioning or issue.
T-4.250.931 REV-A
Page 10 of 19
Q A T A R
Doc. Title
Doc. No:
GAM-PRO-QAC-GTL-038 Rev. D
Date
21.04.08
Date
Brand
AWS class
Batch number
Size
Quantity
Oven number
Treatment temperature
Time when electrodes reach soak temperature
Time of removal from baking oven.
T-4.250.931 REV-A
Page 11 of 19
Q A T A R
Doc. Title
Doc. No:
GAM-PRO-QAC-GTL-038 Rev. D
Date
21.04.08
WELDING GASES
Gases used for weld protection purposes shall be of the welding grade composition
having purity, as defined on the relevant WPS's.
Protective gasses must be issued with appropriate conformance certificates and must
be stored as per vendor's recommendations.
The following provides guidance for the most commonly used gasses in welding:
Composition Table:
Composition
Oxygen
Hydrogen
Nitrogen
Argon
Percent by value
Minimum
N/A
N/A
N/A
99.9
Maximum
0.005
0.005
0.005
100
Argon shall not contain more than 0.02 mm of vapour water per litre of gas measured at
21.1C at 1 atm absolute, or have a dew point of -53.8C or colder.
T-4.250.931 REV-A
Page 12 of 19
Q A T A R
Doc. Title
Doc. No:
GAM-PRO-QAC-GTL-038 Rev. D
Date
21.04.08
T-4.250.931 REV-A
Page 13 of 19
Q A T A R
Doc. Title
Doc. No:
GAM-PRO-QAC-GTL-038 Rev. D
Date
21.04.08
13. ATTACHMENTS
GAM-QCR-QAC-GTL-060
GAM-QCR-QAC-GTL-061
GAM-QCR-QAC-GTL-062
GAM-QCR-QAC-GTL-063
GAM-QCR-QAC-GTL-082
T-4.250.931 REV-A
Page 14 of 19
Q A T A R
Subcontract Ref.:
Report No.
Item Description:
Inspection Date:
Subsystem:
ITP No.:
DATE
WELDING
SIZE
ELECTRODES IN MM
AWS CLASS
Accepted By
ORGANIZATIONS
THIRD PARTY REP.
GAMA REP.
LINDE REP.
QSGTL REP.
GAM-QCR-QAC-GTL-060
ISSUE
QUANTITY
WELDER NO
DATE
NAME
RETURN
SIGNATURE
ELECTRODE
OF WELDER
(WHITE PAINT)
SIGNATURE
SIGNATURE OF
CONSUMABLE
STORE MAN
QATAR
Subcontract Ref.:
Report No.
Item Description:
Inspection
Date:
Subsystem:
ITP No.:
Ref. DWG /
Documents:
Used Measuring and test equipment ref. (if applicable):
S.NO
DATE
INSTRUMENT ID
Accepted By
ORGANIZATIONS
THIRD PARTY REP.
GAMA REP.
LINDE REP.
QSGTL REP.
GAM-QCR-QAC-GTL-061
DATE
HOURS
SIGNATURE
TEMPERATURE
HUMIDITY
NAME
SIGNATURE
QATAR
Subcontract Ref.:
Report No.
Item Description:
Inspection
Date:
Subsystem:
ITP No.:
Ref. DWG /
Documents:
Used Measuring and test equipment ref. (if applicable):
DATE
WELDING
SIZE IN
ELECTRODES
QUANTITY
MM
AWS CLASS
Accepted By
ORGANIZATIONS
THIRD PARTY REP.
GAMA REP.
LINDE REP.
QSGTL REP.
GAM-QCR-QAC-GTL-062
DATE
HOURS
HOLDING
OVEN NUMBER BATCH NO
TEMPERATURE
NAME
SIGNATURE
SIGNATURE
QATAR
Subcontract Ref.:
Report No.
Item Description:
Inspection
Date:
Subsystem:
ITP No.:
Ref. DWG /
Documents:
Used Measuring and test equipment ref. (if applicable):
DATE
WELDING
SIZE IN
ELECTRODES
QUANTITY
MM
AWS CLASS
Accepted By
ORGANIZATIONS
THIRD PARTY REP.
GAMA REP.
LINDE REP.
QSGTL REP.
GAM-QCR-QAC-GTL-063
DATE
HOURS
BAKING
OVEN NUMBER BATCH NO
TEMPERATURE
NAME
SIGNATURE
SIGNATURE
Q A T A R
Item Description:
Iso.No :
Area :
SR.NO BATCH NO
AWS CLASS
DESCRIPTION
DATE
REQUESTED BY
ISSUED BY
CHECKED BY
GAM-QCR-QAC-GTL-082
DIA - mm
NAME
QTY REQUESTED
QTY ISSUED
SIGNATURE